Neck Isolator for Aseptic Container Sterilization
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Solution Overview
Problem
Aseptic bottling lines face challenges with complex structures, large sterile zones, and difficulties in maintaining sterile conditions, leading to lengthy sterilization processes and increased downtime due to the need for extensive sterilization of volumes and manual procedures.
Innovation Solution
A process station with a concave shell that partially envelops the neck of thermoplastic containers to create a controlled treatment volume, using a plasma generator or sterile air to prevent contamination, and UV lamps for decontamination, allowing for continuous protection and reduced sterilization volumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clean room is used to enclose the entire filling apparatus and process zones, then sterile conditions are maintained, but the volume becomes considerable requiring lengthy and costly sterilization procedures
Solution Approach 1:
The patent divides the clean room into multiple isolated zones (first clean room for forming, second clean room for filling/capping) that are separated and independently sterilizable. This segmentation allows each zone to be sterilized separately rather than requiring sterilization of a large unified space, reducing overall sterilization time and cost while maintaining sterile conditions in each zone.
2Reliability
If a clean room is used to enclose the filling apparatus, then sterile conditions are maintained, but considerable waste of working fluids such as sanitizing liquids and sterile air occurs
Solution Approach 1:
By segmenting the clean room into isolated zones with controlled access, the patent prevents the unnecessary dissipation of sterile air and sanitizing liquids across the entire facility. Each zone maintains its sterile environment independently, reducing the total volume of working fluids required and minimizing waste from continuous sterilization of large spaces.
3Reliability
If a clean room is used, then sterile conditions are maintained, but wear-related phenomena occur affecting filters needed for air purification
Solution Approach 1:
The patent divides the air purification system into separate filtration units for each isolated clean room zone. This segmentation reduces the total filtration capacity required in each unit compared to a single large clean room, decreasing wear on filters and extending their service life while maintaining sterile conditions in each zone.
4Reliability
If a clean room is used, then sterile conditions are maintained, but difficulty is involved in performing procedures for format changes, maintenance or adjustments of machine parts
Solution Approach 1:
The patent designs each isolated clean room zone with controlled access points that can be opened for maintenance and format changes. Since zones are segmented and not part of a single large enclosed space, operators can access specific machines in specific zones without compromising the sterile environment of other zones, making maintenance easier while preserving sterile conditions.
5Ease of operation
If the isolator access door is opened for manual procedures, then procedures can be performed, but sterile conditions are lost requiring restoration time
Solution Approach 1:
The patent segments the production line into multiple isolated clean room zones, each with its own controlled access. This allows manual procedures to be performed in one zone without affecting the sterile conditions in other zones. The segmentation minimizes the impact of door openings on overall sterility and reduces the time required to restore sterile conditions after maintenance.
6Volume of stationary object
If a neck-ring isolator is used to cover areas around the neck of containers, then sterilization volume is reduced, but auxiliary members and elements must be arranged within the same volume
Solution Approach 1:
The patent replaces the single neck-ring isolator with multiple isolated clean room zones, each covering specific process stations. This segmentation distributes the auxiliary members and elements across different zones rather than concentrating them in one volume, reducing the sterilization volume per zone while avoiding the complexity of accommodating all auxiliary equipment in a single isolator.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the volumes to be sterilized and the time required for sterilization, enabling faster and easier container production and packaging while maintaining sterile conditions, simplifying maintenance and format changes, and minimizing downtime.
Implementation Method 1
the source of fluid consists in a plasma generator
Implementation Method 2
at least one UV lamp is present and operatively active on the volume to be treated so as to decontaminate it
Data Source
AI summary
A process station (1) for a parison or a container (2) made of thermoplastic material, comprising: a concave shell (3) configured to be applied onto the mouth (2b) of the individual parison or container (2) in such a manner as to enwrap at least partially the neck (2a) of the parison or container (2) so as to delimit a volume for treatment (4) of the neck (2a) subjected to plasma balls immersed in a carrier gas stream.